radar sensor

Abstract

A radar sensor (10), in particular for use in a vehicle, is proposed, having at least one conductor plate (6) and at least one antenna (7), in particular embodied as a waveguide antenna, wherein the antenna (7) is connected to the conductor plate (6), and the connection between the conductor plate (6) and the antenna (7) is implemented by means of a frame (1) which is fastened on the conductor plate (6) and presses the antenna (7) face-wise onto the conductor plate (6).

Description

Technical Field

[0001] This invention relates to a radar sensor, particularly for use in vehicles, having at least one conductor plate and at least one antenna, the antenna being particularly implemented as a waveguide antenna. The antenna is connected to the conductor plate, and the connection between the conductor plate and the antenna is achieved by means of a frame fastened to the conductor plate and pressing the antenna against the conductor plate. Background Technology

[0002] For many years, existing radar sensors on the market have consisted of a conductor plate with a planar antenna, which is structured on the top copper layer and automatically fixed to the conductor plate.

[0003] Currently, radar sensors are being developed in which the conductor plate is not connected to a separate antenna (especially a waveguide antenna). To ensure the operation of the radar sensor throughout its product lifespan, this connection must be permanently, electrically, and robustly configured. Summary of the Invention

[0004] The core of this invention is to propose a radar sensor consisting of at least one conductor plate and at least one antenna, and to provide particularly advantageous connection and assembly feasibility between at least one conductor plate and at least one antenna.

[0005] Furthermore, it is advantageous that the radar sensor (particularly suitable for use in vehicles) has at least one conductor plate and at least one antenna. Here, the antenna can be particularly advantageously implemented as a waveguide antenna. The antenna is connected to the conductor plate, and the connection between the conductor plate and the antenna is achieved by means of a frame. The frame is preferably fastened to at least one conductor plate and presses the antenna onto the conductor plate.

[0006] Preferably, the antenna is placed on a conductor plate. It is particularly advantageous here that the antenna is placed flatly on the conductor plate and / or pressed flatly onto the conductor plate by means of force pressing the antenna and the conductor plate together.

[0007] A further advantage is that the frame is positioned on the outer edge of the antenna. This allows the holding force to be applied evenly to the antenna at the outer edge, resulting in a very uniform distribution of the holding force and permanent positioning under minimal mechanical stress.

[0008] Advantageously, the antenna is permanently fixed to the conductor plate by force locking only with the frame. Therefore, no additional fastening is required by means of brazing, bonding, bolting, riveting, or similar joining processes, thus avoiding mechanical loads and the resulting dimensional accuracy deviations.

[0009] The frame is particularly advantageously made of sheet metal. Sheet metal is advantageous in terms of material cost and is elastic, without permanent deformation. Therefore, it can generate a pressing force that can be maintained for a long time. Further advantageously, the frame is manufactured from sheet metal as a stamped and / or bent metal part. This is simple and inexpensive to manufacture.

[0010] Preferably, the frame has a plurality of press-fit pins (3) on the side facing the conductor plate. These press-fit pins may be manufactured integrally with the frame during the manufacturing process, or attached by a joining process (e.g., by welding or brazing) after the frame is manufactured. Press-fit pins are known in the field of electronics manufacturing and are commonly used for contact with electrical conductor lines in a manner in which a hole exists in the conductor line area of ​​the conductor plate, a needle-shaped press-fit pin is pressed into the hole, and the press-fit pin is spring-loaded and elastically anchored within the hole.

[0011] Advantageously, the frame has mechanical stops on the side facing the conductor plate, which prevent the press-in pin from being pressed too deeply into the conductor plate. These mechanical stops ensure that the distance between the frame and the conductor plate, and thus the pressing force by which the antenna is pressed against the conductor plate, is neither too great nor too small. Another function of the mechanical stops is to ensure that the press-in pin is pressed into the conductor plate to an ideal depth within the conductor plate with its clamping area. These mechanical stops may be arranged in a ring around the edge of the frame or may be provided at only a single location on the frame. Advantageously, mechanical stops are provided at at least three locations to prevent the frame from tilting after reaching the mechanical stops. It is particularly advantageous, given the rectangular shape of the frame, to provide four mechanical stops on the frame, particularly advantageously at the corners of the frame. According to another embodiment, mechanical stops may also be provided in the area of ​​the press-in pin.

[0012] A further advantage is that the frame has a recess on the side opposite to the conductor plate (i.e., the transmitting and receiving side of the sensor) at a location where the antenna has transmitting and receiving openings. For this purpose, the frame has at least one or more locations in its internal region with through-holes, recesses, or windows, such that the antenna aperture is not obscured by the frame.

[0013] Advantageously, the frame may also have a spring tongue on the side opposite to the conductor plate, which is placed on the opposite side of the antenna and presses the antenna against the conductor plate. Here, the spring tongue may be formed as a groove or a curved groove, allowing the frame to press the antenna against the conductor plate with a predetermined force. The spring tongue may be formed from a sheet material of the frame. Advantageously, the spring tongue is parallel to the following surface of the antenna, which is aligned with the side opposite to the conductor plate.

[0014] A further advantage is that the antenna has a support surface in its edge region, on which the spring tongue of the frame is placed and through which pressure is applied to the antenna.

[0015] The mounting surface may have an edge profile, such as an edge profile in the form of a recess in an antenna, so that the spring tongue is placed in the edge profile or the recess on the antenna and does not slip relative to each other due to the edge of the profile or the recess.

[0016] Advantageously, the retaining force of all the push-in pins is significantly greater than the pressing force of all the spring tongues. This ensures that the spring force (which attempts to pull the push-in pins out of the conductor plate in its reaction force) is not large enough to pull the push-in pins out. It is particularly advantageous that the retaining force of all the push-in pins is approximately 2 to 10 times, especially 3 to 5 times, the opposing spring force of the spring tongues.

[0017] Advantageously, the antenna has a centering body on the side facing the conductor plate, the centering body being formed at the contact surface with the conductor plate such that the centering body acts in a hole in the conductor plate and ensures the relative positioning of the antenna with respect to the conductor plate.

[0018] Here, the centering body can be particularly advantageously implemented as a centering pin, especially in the form of a circular centering pin, and the hole in the conductor plate is a circular hole with approximately the same diameter as the circular centering pin. The centering pin and the hole advantageously form a mating relationship with each other by their diameters, and advantageously have sufficient tolerances.

[0019] A further advantage is that the antenna has a conductive metallization coated on its outer side, and the metallization is connected to the electrical grounding terminal of the conductor plate via a conductive frame. This configuration enables the conductor plate and the antenna to be at the same grounding potential without requiring additional connections, brazing, or other connection processes.

[0020] Advantageously, at least one electronic structural element is mounted on the conductor plate. Thus, only a single conductor plate is required, as it can house the electronic components for both the transmitting and receiving circuits, while simultaneously establishing contact with the antenna. This achieves a cost-effective and space-saving structural design.

[0021] Other features, applicability, and advantages of the present invention will become apparent from the following description of embodiments of the invention, which are illustrated in the accompanying drawings. Herein, all features described or illustrated, either alone or in any combination, constitute the subject matter of the invention, regardless of their combination in the claims or their references, and also regardless of their representation or presentation in the specification or drawings. Attached Figure Description

[0022] The embodiments of the present invention will be described below with reference to the accompanying drawings. These drawings show: Figure 1 A perspective view of an exemplary implementation of the frame; Figure 2 Another perspective view of one embodiment of the device according to the invention (having a conductor plate, an antenna, and a frame); Figure 3 An exemplary embodiment of the frame's spring tongue and antenna detailed view; Figure 4 A top view of an exemplary embodiment in which the frame is mounted on a conductor plate with an antenna; Figure 5 A schematic side view of an exemplary embodiment in its assembled state. Detailed Implementation

[0023] Figure 1 A frame 1, as part of a radar sensor according to the invention, is shown. Here, the frame 1 is used for a permanent and planar connection between the waveguide antenna 7 and the conductor plate 6. For this purpose, the illustrated frame 1 is used when assembling the sensor; the frame is made, for example, of sheet metal. For this purpose, the frame 1 is, for example, punched from sheet metal, or... Figure 1 The bending process, as shown, produces a right-angled frame 1 with one or more recesses in the "cover area" and frame edges 2 (advantageously four frame edges 2). The bent frame edges 2 provide the frame 1 with extremely high stability relative to the overall frame 1. Press-in pins 3 are present on multiple sides of the frame (advantageously three or four locations). The press-in pins 3 can be punched during manufacturing, thus making them integral with the frame 1. Alternatively, the press-in pins 3 can be manufactured separately, and in some manufacturing steps, they can be fused or brazed to the frame 1. The press-in pins 3 are installed such that they enable the frame 1 to be parallel to the conductor plate 6 with its central face. Figure 1 (Not shown in the image) is fixed.

[0024] In one implementation, in addition to the press-in pin 3, a press-in stop 4 is also provided. These press-in stops 4 have a terminating edge in the press-in direction, which, when the press-in pin 3 reaches the desired press-in depth, rests on the conductor plate 6, thereby preventing further or deeper press-in of the press-in pin 3. Thus, the press-in pin 3 can be fixed at its optimal effective press-in depth. The press-in stops 4 are not necessarily located near the press-in pin 3; the press-in pin can also be located away from the press-in pin 3.

[0025] According to another embodiment, a spring tongue 5 may be provided on the frame 1. With a correspondingly selected shape for the antenna 7 (waveguide antenna), the spring tongue 5 can press the waveguide antenna 7 against the conductor plate 6. Here, the spring tongue 5 is laterally bent within the limits of the elastic material by the reaction force generated by the waveguide antenna 7, thereby causing the spring tongue 5 of the frame 1 to generate a predetermined pressing force. These spring tongues 5 may, for example, be molded on the upper side of the frame 1 in the area of ​​the opening (through which the waveguide antenna 7 transmits and receives signals).

[0026] Figure 2 It shows Figure 1 The image shows a side view of the frame, in which the conductor plate 6 and waveguide antenna 7 are assembled with the frame 1. The conductor plate 6 is visible at the bottom; however, the conductor lines and brazed components that may be present on this conductor plate are not shown. In practical applications, the conductor plate 6 typically includes conductor lines, via contacts, and brazed structural elements.

[0027] An antenna 7 is placed on the conductor plate 6, which is implemented here as a waveguide antenna or Waveguide-Antenne. The waveguide antenna is made of a specific material with channels within it, which guide electromagnetic waves inside the waveguide antenna 7. The dimensions of the channels must be manufactured with great precision, otherwise the frequency of the guided electromagnetic waves will be altered. The material of the waveguide antenna 7 is typically a metal. However, it is also possible to use other conductive materials as the material of the waveguide antenna 7, or the waveguide antenna can be made of a non-conductive material (such as plastic) with a metallized layer, wherein at least the surface of the waveguide channel is metallized.

[0028] The waveguide antenna 7 and the conductor plate 6 are stacked on top of each other, making them in contact, especially in a surface contact. However, the two parts are not brazed or glued to each other, but are permanently connected to each other through the frame 1.

[0029] To this end, frame 1 is placed on waveguide antenna 7, and the press-in pin 3 of frame 1 is pressed into the corresponding hole in conductor plate 6. By pressing in the press-in pin 3, waveguide antenna 7 is pressed onto conductor plate 6 and permanently held there. Here, press-in stop 4 ensures that the press-in pin 3 of frame 1 is neither pressed too deeply into the hole in conductor plate 6 nor pressed in too shallowly. The press-in stop 4 on frame 1 allows the press-in pin 3 to be pressed in by overpressure, and the correct press-in depth is achieved when the press-in stop 4 is seated on conductor plate 6.

[0030] Furthermore, a spring tongue 5 may be provided in the upper region of the frame 1, the spring tongue being placed on a suitable edge of the waveguide antenna 7. By pressing the frame in and placing the waveguide antenna 7 on the conductor plate 6, the spring tongue 5 placed on the waveguide antenna 7 will elastically deform, thereby generating a spring force. Figure 2As can be seen, the spring tongue 5 bends upward, thereby applying a sustained and predefined force to the waveguide antenna 7, which presses the waveguide antenna 7 against the conductor plate 6. Consequently, the spring tongue 5 bends beyond the plane defined by the edge 2 of the frame 1. In the claimed structure, the waveguide antenna 7 does not slip laterally on the conductor plate 6 because the frame is held in a form-locked manner by the press-fit pins 3 pressed into the conductor plate 6 to prevent slippage parallel to the conductor plate 6, and the frame cannot be displaced without structural damage.

[0031] A recess can be provided in the waveguide antenna 7 so that the end of the spring tongue 5 is precisely embedded in the recess, thereby preventing the waveguide antenna 7 from shifting relative to the frame 1.

[0032] The frame 1 is opened at at least one location in its center, allowing electromagnetic waves transmitted or received by the waveguide antenna 7 to pass through unobstructed. Depending on the implementation of the waveguide antenna 7, for example, a portion of the antenna module may protrude through this opening. The antenna opening 8 (often also referred to as the antenna aperture 8) of the waveguide antenna 7 is located on the upper side of the waveguide antenna 7, and the frame 1 is configured such that it does not impede transmission or reception performance.

[0033] Figure 3 Another embodiment of the component according to the invention is shown. It further shows a conductor plate 6, which may have conductive lines and structural elements not shown. A waveguide antenna 7 is placed on the conductor plate 6. Here, the supporting area of ​​the waveguide antenna 7 can be a large area of ​​the entire lower side, or alternatively, it can be configured as a supporting region 16, consisting only of a small portion or several small portions of the lower side of the waveguide antenna 7. For example, advantageously, only the portion of the lower side of the waveguide antenna 7 can be configured as the supporting region 16, in which a transition region exists where electromagnetic signals are coupled (or decoupled) from the conductor plate 6 to the waveguide antenna 7. The advantage of this variation, where only a portion of the lower side of the waveguide antenna 7 is configured as the supporting surface 16, is that the supporting region 16 exists only around the area of ​​the coupling structure, can withstand greater pressing force, and thus can more effectively avoid possible air gaps (which may be generated, for example, by thermal stress) between the conductor plate 6 and the waveguide antenna 7.

[0034] Figure 3 The left portion shows frame 1, which is pressed into the hole of conductor plate 6 by its molded press-in pin 3. At the upper left edge of frame 1, a curved edge 2 of the frame can be seen, where the vertical portion (with press-in pin 3) transitions into the flat upper region (“cover region”) of frame 1. The upper cover region of frame 1 has at least one opening through which the upper side of waveguide antenna 7 can extend, through which electromagnetic signals of waveguide antenna 7 can be transmitted and received. Figure 3The side region of frame 1 is shown in dashed lines in this area, which is located outside the cross-section shown in the figure.

[0035] Furthermore, a waveguide antenna 7 is shown, which is typically composed of and assembled from two sub-shells. A mounting surface 12 is shown in the upper half of the waveguide antenna 7, on which the spring tongue 5 of the frame 1 rests. The mounting surface 12 of the waveguide antenna 7 can be presented and shaped as follows: Figure 2 The raised shape shown can also be implemented as a deep recess or groove formed in the outer contour of the waveguide antenna 7, in the region of the upper edge of the waveguide antenna 7. In the variation, the spring tongue 5 is placed on the support surface 12 of the formed part and bends in the region of elastic deformation of the spring tongue 5 (as shown). Through this elastic deformation, the spring tongue 5 generates a pressing force that acts on the waveguide antenna 7, and the waveguide antenna 7 is pressed vertically and persistently against the conductor plate 6.

[0036] As another implementation method Figure 3 The centering body 9 is shown in the lower part of the figure. This centering body 9 can be integrally formed on the underside of the waveguide antenna 7, and has, for example, a diameter that precisely fits into the hole 11 in the conductor plate 6, which serves as a centering aperture. The hole 11 in the conductor plate 6 can here be configured as a mating part with respect to the centering body 9, so that even with only a small pressing force from the waveguide antenna 7 onto the conductor plate 6, the two components will not slip relative to each other.

[0037] Figure 4 Another embodiment variation is also shown, in which the frame has not only one recess but also multiple recesses (e.g., two recesses) on its upper side (cover side). A conductor plate 6 is also shown, which may have conductor lines and structural elements not shown. The frame 1 presses against the conductor plate 6. Figure 4 In the diagram, the frame is indicated by a diagonal shading. Frame 1 secures the waveguide antenna 7 to the conductor plate 6 by means of four spring tabs 5 shown. The antenna aperture 8 is shown on the upper side of the waveguide antenna 7, which can be arranged, for example, in the form of an antenna array. If the arrangement of the antenna aperture 8 allows, frame 1 can be modified to have a spring beam 13, which divides the opening of frame 1 at the "cover side" of frame 1 into two sub-openings. The spring beam 13 divides the opening in frame 1, and through this spring beam, frame 1 has greater stiffness and reduces torsion under load. Another advantage is that the middle of the spring beam 13 can apply elastic pressure to the middle of the waveguide antenna 7, thereby supporting the spring tabs 5 and distributing the pressing pressure 15 more evenly on the waveguide antenna 7. For example, in this configuration, the spring tabs 5 at the edges of frame 1 can even be omitted entirely.

[0038] Figure 5Another variation is shown to enhance the effect of the centering pressing force 15 of the spring beam 13 of frame 1. Figure 5 The diagram shows a conductor plate 6 and a waveguide antenna 7. The waveguide antenna 7 is placed on the conductor plate 6 via one or more mounting areas 16. Alternatively, the waveguide antenna 7 can be placed planarly on the conductor plate 6. The waveguide antenna 7 is secured by a frame 1, which is pressed into holes in the conductor plate 6 by press-fit pins 3 at its edges. The frame 1 has one or more openings at its top through which the antenna aperture 8 can transmit and receive electromagnetic radiation.

[0039] To apply pressure 15 at a specific location on the waveguide antenna 7, or to increase the pressure applied through the frame 1, a lens-shaped protrusion 14 or a pressure block 14 can be installed on the upper side of the waveguide antenna 7 (i.e., in the region of the spring beam 13). This pressure block 14 is located below the spring beam 13, allowing the elastically yielding spring beam 13 of the frame 1 to apply pressure to the lens-shaped pressure block 14, and enabling the pressure 15 of the waveguide antenna 7 to be applied with extremely high point precision.

[0040] Figure 5 In the diagram, the various components (conductor plate 6, waveguide antenna 7, frame 1) are shown as not in contact, as they are shown in an exploded view. In the assembled state, the waveguide antenna 7 is placed on the conductor plate 6, while the frame 1 presses its spring beam 13 against the pressure block 14, deforming the spring beam 13 and applying a pressing force 15 to the pressure block 14.

Claims

1. A radar sensor (10), particularly for use in vehicles, having: - At least one conductor plate (6); - At least one antenna (7), said antenna being particularly implemented as a waveguide antenna; in, The antenna (7) is connected to the conductor plate (6). Its features are, The connection between the conductor plate (6) and the antenna (7) is achieved by means of the frame (1). The frame is fastened to the conductor plate (6), and the frame presses the antenna (7) onto the conductor plate (6).

2. The radar sensor (10) according to claim 1, characterized in that, The antenna (7) is placed on the conductor plate (6).

3. The radar sensor (10) according to claim 1 or 2, characterized in that, The antenna (7) is placed face up on the conductor plate (6) or pressed face up onto the conductor plate.

4. The radar sensor (10) according to any one of the preceding claims, characterized in that, The frame (1) is mainly placed on the antenna (7) at the outer edge (12) of the antenna (7).

5. The radar sensor (10) according to any one of the preceding claims, characterized in that, The antenna (7) is permanently fixed on the conductor plate (6) by force locking of the frame (1).

6. The radar sensor (10) according to any one of the preceding claims, characterized in that, The frame (1) is made of sheet metal, particularly of metal stampings and / or bending.

7. The radar sensor (10) according to any one of the preceding claims, characterized in that, The frame (1) has a plurality of press-fit pins (3) on one side facing the conductor plate (6), the press-fit pins being pressed into holes in the conductor plate (6), and in particular, the press-fit pins (3) being integrally implemented with the frame (1).

8. The radar sensor (10) according to any one of the preceding claims, characterized in that, The frame (1) has a mechanical stop (4) on the side facing the conductor plate (6), which prevents the press-in pin (3) from being pressed too deeply into the conductor plate (6).

9. The radar sensor (10) according to any one of the preceding claims, characterized in that, The frame (1) has a recess on the side opposite to the conductor plate (6) (i.e., the transmitting and receiving side of the sensor (10)) at a location where the antenna has a transmitting and receiving opening (8).

10. The radar sensor (10) according to any one of the preceding claims, characterized in that, The frame (1) has a spring tongue (5) on the side away from the conductor plate (6), the spring tongue is placed on the side of the antenna (7) away from the conductor plate (6) and presses the antenna (7) onto the conductor plate (6).

11. The radar sensor (10) according to any one of the preceding claims, characterized in that, The antenna (7) has a support surface (12) at its edge region, the spring tongue (12) of the frame (1) is placed on the support surface, and pressure is applied to the antenna (7) through the support surface.

12. The radar sensor (10) according to any one of the preceding claims, characterized in that, The holding force of all the press-in pins (3) is significantly greater than the pressing force of all the spring tongues (5), especially the holding force of the press-in pins (3) is 2 to 10 times, especially 3 to 5 times, the spring force of the spring tongues (5).

13. The radar sensor (10) according to any one of the preceding claims, characterized in that, The antenna (7) has a centering body (9) on the side facing the conductor plate (6), the centering body being formed at the contact surface with the conductor plate (6) such that the centering body (9) acts in the hole (11) of the conductor plate (6) and ensures the relative positioning of the antenna (7) with respect to the conductor plate (6).

14. The radar sensor (10) according to any one of the preceding claims, characterized in that, The antenna (7) has a conductive metallized portion coated on its outer side, and the metallized portion of the antenna (7) is connected to the electrical grounding terminal of the conductor plate (6) through a conductive frame (1).

15. The radar sensor (10) according to any one of the preceding claims, characterized in that, At least one electronic structural element (17) is mounted on the conductor plate (6).

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